Method for manufacturing anodes

ABSTRACT

A method for assembling anodes used in electro winning processes, that increases corrosion resistance, comprising pre-coating the copper bus bar by being cast plated at the adequate temperature, introducing said copper bar into an adequate mold and, by injection or a similar method the copper bar is peripherally coated with a lead-antimony alloy, moving the copper bar to the assembly table, and filling the slot with a lead-bismuth alloy, applying, once the lead-bismuth alloy poured into the slot has solidified, reinforcement solder,

FIELD OF THE INVENTION

This invention relates to a coating method or process for manufacturing anodes used in highly pure-metal high-electrowinning or electrorefining processes representing improved characteristics with respect to anodes and to currently known manufacturing methods.

BACKGROUND OF THE INVENTION

It is known that the use of the metal electrowinning and electrorefining process dates back to the 1860's. This technology has further developed to date, where, with the advent of the solvent extraction technology, anodes bear a copper bar to conduct the current, comprising the positive anode for electrowinning purposes.

Two assembled systems have prevailed to date, at the joint between the bus bar-body and the anode, the former known as RSR method, and the former as the Royston method, which correspond to the two companies that developed these methods over two decades ago.

The aforementioned systems are briefly described below:

-   a) RSR method (see FIGS. 1 and 2): the copper support bar (1), has a     slot (2) throughout its straight 6-12 mm wide×199 mm deep×940 mm     long portion (R), into which the laminated plate (3) is inserted. A     coating (4 a) has been previously made, (FIG. 3) on the copper     support bar (1) with a Pb=52%; Sn=45%; Sb=3% alloy, and the slot (3)     has been filled with the same alloy (4 b); being later soldered to     each other (support bar and lead plate), by solder (5), FIG. 4,     Pb=94%; Sb=6%; and finally, the entire head of the anode, that is     the bus bar, the solder zone and 50 mm, approximately, of the sheet     below the solder zone, is covered with a electrowinning deposit of     pure lead of up to 0.75 mm. of thickness. -   b) Royston method (see FIG. 5): the entire perimeter of the copper     support bar (8) is coated with a lead-antimony-based alloy (7),     preferably 6% Sb, at least 6 mm thick, and the sheet (10) is later     attached to the coating (7) by using solder (9), of an alloy     identical to that of the peripheral coating.

The manufacture of anodes through the aforementioned methods, in practice, has shown different mechanical and structural deficiencies over the past two decades, which may be summarized as follows:

-   I).—An anode with poor conductivity in the Royston system, because     the sheet is not directly soldered to the copper bar, but to its     coating, and -   II).—in the RSR system, structural distortion in electrowinning     processes, and corrosion through the electrowinning lead coating on     the copper bar, causing 1.—structural distortion, serious warping     problem (anode concave bending) with subsequent occurrence of     short-circuits; and 2.—contact problems and, eventually, bar-plate     detachment due to corrosion. -   The RSR-like joint system is the one showing better conductivity,     but it clearly makes apparent, in turn, the conceptual failure of     the anode assembly method, which causes this system to cause such a     negative bending, of great technical and economic significance to     mining users, which, due to process replacement, must be stopped,     causing refinery productivity to drop. The RSR system shows     significant corrosion on the anode head within the first year of     operation, from the destruction of the 0.75 mm thick pure lead     electrowinning deposit resulting from the solder on the copper bar     that acts as a adhesive element.

There is also the system disclosed in Chilean patent CL42634, which refers to an assembly and construction method for anodes used in electrowinning processes, comprising a copper bus bar in which a slot whose thickness is 0.12 mm more than the thickness of the lead bar that will be fitted into it has been previously milled. Said copper bus bar is pre-coated by being submerged in an alloy sheet, preferably Lead between 25% and 27.5%, Bismuth between 25% and 27.5% and between 45% and 50% of Tin, all at 170° C. Then, the bar is moved to the assembly table where the slot is filled with the same cast alloy and at the same temperature, and the lead sheet is immediately introduced. The copper bar starts to cool down while the lead sheet at the joint area starts to heat. After a short period of time, a thermal balance between both bodies is established at 135° C., and both start to cool down from that temperature, their expansion being identical.

When the temperature of the set at the joint area has reached 100° C., reinforcement solder is applied to said area on both sides. Said solder consists of a rod solder bead between the copper bar and the lead sheet walls, which alloy is lead-bismuth, with up to 55% of bismuth. With this system copper bar bending is prevented, since the tension generated by the differential contraction between the copper bar and the lead sheet.

SUMMARY OF THE INVENTION

The method of the present invention proposes a manufacture technology that solves all the negative aspects in the aforementioned systems, proposing a structural anode having functionally improved conductivity and excellent corrosion rates, without bending and without detachment of the copper joining bar-lead sheet, achieving said characteristics by way of substantial modifications to the design of the alloys used, where the absence of Tin is their core constituent, in which the level of corrosion is high, as well as on the coating of the anode's copper bar, which no longer is pure lead electrolitically deposited but a cast and thicker lead-antimony alloy, strongly attached by the metallurgical joint between the silver-based solder and the Lead-Antimony coating, unlike the joint resulting from the pure lead electrolytic coating, which is substantially mechanically weaker, in addition to being porous, which causes more intense corrosion. This assembly method improves these aspects and conceptually keeps the bar-body joint with low melting-point solder to prevent bending.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a complete anode.

FIG. 2 shows the slotted copper bar in cuts A and B.

FIG. 3 shows the pre-assembled anode after slot has been filled with wed and the lead sheet has been inserted.

FIG. 4 shows the assembled anode finished with reinforcement solder.

FIG. 5 shows the assembled Royston-like anode.

DESCRIPTION OF THE INVENTION

The invention relates to a method for assembling and manufacturing anodes used in electrowinning processes, comprising a copper bus bar (1) which a slot (2), where a slot whose thickness is 0.12 mm more than the thickness of the lead bar that will be fitted into the sheet (3), and which is approximately 19 mm deep, has been previously milled. Said copper bus bar (1) is first solder coated by being pre-coated with a Lead-Silver base alloy, preferably Lead: 97%, Silver: 3%, (4 a) at an adequate temperature (300-350° C.) FIGS. 3 and 4, and immediately after, and with the newly coated bar at a 250 to 280° C. temperature, it is introduced into an adequate mold, and through injection or another similar mechanism, the bar is peripherally coated with a 0 to 10% Sb thick Lead-Antimony alloy, preferably 6%, and preferably with a 0.01 and 10 mm thickness, preferably 1.5 mm, (6) FIGS. 3 and 4. Then, copper bar, that has been peripherally coated with the Lead-Antimony alloy and still hot, is placed on an adequate assembly table where the slot (2) is filled with a low-melting point cast lead-bismuth alloy, (4 b) FIGS. 3 and 4, preferably Lead: 50%-Bismuth: 50%. The Lead-Bismuth solder must be at such temperature that it allows the lead plate to be introduced into the assembly slot, keeping the Lead-Bismuth solder in an absolute liquid state. The lead plate (3) is introduced in to the slot in the copper bar, filled with solder (4 b). The copper bar (1) starts to cool down, whereas the plate (3) starts to heat. After a short period of time, a thermal balance between both bodies is established at about 135-150° C., and both start to cool down from that temperature, being identically expanded. This will ensure that tension will not be generated ad the soldered joint, which is the cause of subsequent anode bending.

When the temperature of the set at the joint area has reached abut 100° C., and the solder (4 b) had solidified, the reinforcement solder (5) is applied to said area and on both sides. Said solder (5) consists of a rod or rodless solder bead between the peripheral coating (6) of the copper bar (1) and the plate walls (3); the solder alloy may be a lead-bismuth alloy, which lead content is greater than 50%. 

1. A method for assembling anodes, used in electrowinning processes, that increases corrosion resistance, comprising the following steps: a) pre-coating (4 a) the copper bus bar (1) by being cast plated at the adequate temperature (300° C.-350° C.) with an alloy mainly comprising lead and silver, and where the silver content is between 0.1% and 10%, preferably 3%; b) introducing said copper bar, this coating and the copper bar hot, (250° C.-280° C.) into an adequate mold and, by injection or a similar method, the copper bar is peripherally coated with a 0-11% Sb lead-antimony alloy, preferably 6% of (6), and being 0.01 mm to 10 mm thick, preferably 1.5 mm; c) moving the copper bar (1) to the assembly table, and filling the slot (2) with a lead-bismuth alloy, with 1% to 55% of Bismuth, preferably 50%, (4 b) at an adequate temperature, allowing the lead plate to be introduced, the lead-bismuth remaining is a liquid state; d) applying, once the lead-bismuth alloy poured into the slot (4 b) has solidified, reinforcement solder, preferably with an alloy identical to the one of the peripheral coating, (5) to the joint area between the peripheral coating of the copper bar (6) and the plate (3), on both sides.
 2. A method, according to claim 1, wherein the center of the milled slot in the copper bar is longitudinally parallel to the copper bar.
 3. A method, according to claim 1, wherein the solder, when joining the copper bus bar (1) and the plate (3) takes place once the balance temperature has been reached.
 4. A method, according to claim 1, wherein the reinforcement solder (5) of the bus bar and the lead plate is carried out when the temperature in said pieces is substantially below the alloy's melting point (4 b),
 5. A method, according to claim 1, wherein the solder alloy that reinforces the bar-plate pieces mainly contains lead. 